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1999 GSX Limited won't turn over by hand

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Seadoo99

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Hi all, new here and to Seadoos. I have a 1999 GSX Limited. It quit on us yesterday and won't start. When you try to start it there was just a click or clunk (kind of more like a clunk than click). I thought it was the starter so I took it out. I bench tested it and it turns over great. I then took out the plugs and tried to turn over the engine by hand and it won't budge. Any idea what it might be and what I can check without tearing the motor out? Any help would be greatly appreciated. Thanks in advance.
 
Have you looked in the pump to see if it is clogged?? That would be my first guess. Other than that my only idea would be that it is hydro-locked and the pistons are rusted to the cylinder walls. (maybe try and look in and see if there is any water inside the cylinders)
 
I would start by taking the pump off. Then try turning your engine over by hand with plugs out. If the engine rotates, it's your pump, if your engine still has the problem it's either a top end problem or bottom end problem. Does this ski have the 951 or 787?
 
gsxkid said:
Have you looked in the pump to see if it is clogged?? That would be my first guess. Other than that my only idea would be that it is hydro-locked and the pistons are rusted to the cylinder walls. (maybe try and look in and see if there is any water inside the cylinders)
Click to expand...

Thanks for the suggestions. I already pulled the pump off and it turns freely. The motor still wouldn't turn over. I will see if there is any water in the cylinders but how could water get in if it was just running normally and just stalled? Sorry if this is a noob question but I am new to these. Thanks
 
BMANN06 said:
I would start by taking the pump off. Then try turning your engine over by hand with plugs out. If the engine rotates, it's your pump, if your engine still has the problem it's either a top end problem or bottom end problem. Does this ski have the 951 or 787?
Click to expand...

Already took off the pump and it turns freely but the motor doesn't. It is the 951. Thanks for any help.
 
gsxkid said:
Have you looked in the pump to see if it is clogged?? That would be my first guess. Other than that my only idea would be that it is hydro-locked and the pistons are rusted to the cylinder walls. (maybe try and look in and see if there is any water inside the cylinders)
Click to expand...

It doesn't appear that there is any water in the cylinders. I am guessing this isn't going to be good. The ski only has 92.5 hours on it. We have only had it for about 5 weeks and it has run flawlessly.
 
Hmmm that's weird. If you are feeling adventurous take the top end off and take a look at it. It's not terribly difficult to do, just make sure to follow the correct pattern to tighten the bolts back up and to the correct torque.
 
gsxkid said:
Just thought of it, but is there oil in the tank????
Click to expand...

Yeah, plenty of oil. I am taking off the head now. I have one of the studs that is rusted in so I have some WD-40 working on it. Hopefully I will still get it apart tonight. Thanks again everyone.
 
Well I still can't get the two studs loose but I do have a little more info. Both pistons look good and they both move freely in the head. They will move a very small amount up and down when I move the shaft back and forth (the little bit it will move). It almost seems like something is wedged somewhere. Hopefully not the crank. I will let it set all night as I am whipped and it is after 10pm now. Thanks again and I will post tomorrow as soon as I know something.
 
Seadoo99 said:
Well I still can't get the two studs loose but I do have a little more info. Both pistons look good and they both move freely in the head. They will move a very small amount up and down when I move the shaft back and forth (the little bit it will move). It almost seems like something is wedged somewhere. Hopefully not the crank. I will let it set all night as I am whipped and it is after 10pm now. Thanks again and I will post tomorrow as soon as I know something.
Click to expand...

You probably have a problem in the crank .... You could pull the jugs off and this would confirm. I know it sucks but your this far you may aswell know for sure.

Let us know.
 
BMANN06 said:
You probably have a problem in the crank .... You could pull the jugs off and this would confirm. I know it sucks but your this far you may aswell know for sure.

Let us know.
Click to expand...

Yeah, I haven't had a chance to work on it yet this morning. Of course last week I started a big bathroom project too and I need to get that done before I can go back to the ski. Hopefully later today I can get those two studs off and then pull the jugs and see what is up. I have the jugs loose and ready to come off but without getting the studs off, there isn't enough room to pull it off.
 
Well I just ended up pulling the motor. Not good news. The block has a huge hole in it. I haven't researched enough but is this the cam area (not even sure these have a cam)? What could have caused this to happen? What are my options at this point?

Here are some pics:

166.jpg

167.jpg
 
Oh man that sucks. Scour ebay for a crankcase and then you can core that thing.

You don't have a camshaft, but do have a counterbalance shaft.
 
OK experts...what would cause this to happen?
I've never torn an engine apart except for a 5 Hp from a snow-blower.
 
If you can do a 5hp blower, you can do these. You'll need the shop manual, which can be obtained from this site.
 
BMANN06 said:
Oh man that sucks. Scour ebay for a crankcase and then you can core that thing.

You don't have a camshaft, but do have a counterbalance shaft.
Click to expand...
So that must be the shaft in the open area hey?

I still would like to know what caused it as I don't want to rebuild it and have it happen again.
 
BMANN06 said:
If you can do a 5hp blower, you can do these. You'll need the shop manual, which can be obtained from this site.
Click to expand...

I used to race cars and have rebuilt V8's so I don't think this will be too tough. I do have the shop manual too. I will look on Ebay.

I am in the process of tearing it apart now to see if there is anything else damaged. I think the counterbalance shaft has some issues.
 
More bad news; I took apart the cases and the counterbalance shaft is broke in two. The gear on the crank that drives the counterbalance shaft is shot. Does it make any sense to just go with a rebuilt motor? All help is appreciated.

Pics:
168.jpg

169.jpg
 
WOW, I've never seen such damage. I guess it wasn't the pump nor was it hydrolocked.
Then again, One time I did see the damage that a broken rod did to the block...big hole.
 
Seadoo99 said:
More bad news; I took apart the cases and the counterbalance shaft is broke in two. The gear on the crank that drives the counterbalance shaft is shot. Does it make any sense to just go with a rebuilt motor? All help is appreciated.
Click to expand...

Wow!! What kinda sound did this make when she locked up on you ... I would go with a rebuilt, but most places require you to have a core to exchange with. Is it just the bottom case that blew apart?
 
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